Method And Apparatus For Creating A Pulsed Stream Of Particles

ABSTRACT

A method of producing absorbent articles, comprising: suspending particles in a gas carrier to form suspended particles; creating a series of pulses from the suspended particles, wherein each pulse in the series of pulses is created by: accumulating at least some of the suspended particles in a pulsing chamber to form accumulated particles on a rotary separator, and releasing at least some of the accumulated particles by rotating the rotary separator to create each pulse; and suctioning each pulse from the series of pulses onto a forming surface for the absorbent articles.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of prior U.S. application Ser. No.11/493,313, filed Jul. 26, 2006, which is a divisional of U.S.application Ser. No. 10/423,425, filed Apr. 25, 2003. This applicationincorporates U.S. application Ser. No. 11/493,313 and U.S. applicationSer. No. 10/423,425 by reference.

FIELD OF THE INVENTION

The present invention provides a method and an apparatus for forming apulsed stream of a particulate material, allowing high pulsingfrequencies, and being particularly suitable for the production ofdisposable absorbent articles, such as baby diapers and the like.

The invention is further directed to a kit or pack of individualabsorbent articles which can be produced using the method and theapparatus.

BACKGROUND OF THE INVENTION

Creating constantly and quickly repeating pulses of particulate materialsuspended in a carrier means such as air has been a long lasting desirefor many applications, in particular for pulses which are wellcontrolled with regard to their shape, to their frequency, and to theamount of material transferred during these pulses. A particularlyuseful application is during the manufacture of disposable absorbentarticles, such as baby diapers, adult incontinence or feminine hygienepads, and the like, where the manufacturing aims at high productionspeed and low variability.

In U.S. Pat. No. 4,800,102 (Takada), an apparatus and method forspraying or scattering solid particulate powders onto a substrate isdescribed. The powder is scattered onto a rotatable disc member, whichhas at least one opening through which a portion of the powder can passthrough to reach an underlying substrate, while the non-passing powderis recycled to the powder feeder. Another masking process is describedin PCT publication WO-A-92/19198 (Perneborn). Thereby, a device fordepositing particles on a moving web of material has an apertured beltwhich moves over a material web and has a particle dispenser to dispenseparticles in a uniform pattern in the shape of the apertures of thebelt. The particles not dispensed through the apertures are recycledback to the particle feeder.

Both of these systems use the gravity for accelerating the powderparticles, and are limited in pulse frequency and hence overallproduction speed. Further, as part of the powder delivered to the deviceis recycled, there is only limited control of the amount of powderdisposed on the substrate, and hence in the produced article.

U.S. Pat. No. 5,213,817 (Pelley) describes a powder spray ejectoroscillating over a flow separator, which separates a portion of thepowder being deposited on a web, and the other portion being recycled.

Other approaches use pulsing of an air stream to create a pulsedparticle stream, such as described in U.S. Pat. No. 4,927,346 (Kaiser),U.S. Pat. No. 6,033,199 (Vonderhaar). In U.S. Pat. No. 5,028,224(Pieper) an apparatus and process for providing a pulsed particle streamis described, wherein a continuous gas entrained stream of particles iscentrifugally diverted into an accumulation region, from where it isselectively discharged, such as by the use of a pulsed air stream.

U.S. Pat. No. 4,543,274 (Mulder) discloses a powder spray gun whereinhigh velocity air is said to impact powder entrained air contained inthe bore of the gun. U.S. Pat. No. 4,600,603 (Mulder) discloses a powderspray gun apparatus wherein an inverted flow amplifier is locatedadjacent to the inlet of the gun to enhance blending of powder withinthe gun. From the inverted flow amplifier, the blended powder issupplied to a downstream air flow amplifier which is operable to impactair entrained powder with a high velocity stream of compressed air. Apowder control system controls powder supply from powder supply pumps tothe spray gun. The powder pumps are said to be conventional venturipowder pumps.

U.S. Pat. No. 4,770,344 (Kaiser) discloses a powder spraying systemincluding a volumetric or gravimetric material feeding device formetering a quantity of powder into a manifold, and air flow amplifiersconnected to passageways formed in the manifold. Kaiser '344 teachesthat a problem associated with venturi powder pumps is the difficulty inobtaining a consistently accurate feed rate of powder material,especially when a spray gun is operated intermittently. U.S. Pat. No.4,927,346 and U.S. Pat. No. 5,017,324 (Kaiser) disclose additionalembodiments for depositing particulate material into a pad with a spraygun, including an embodiment having an inverted flow amplifier and anembodiment having a rotating screw for providing a metered quantity ofabsorbent particles. U.S. Pat. No. 5,037,247 (Kaiser) discloses a powderpumping apparatus having a venturi passageway and an air ejectorincluding a valve mechanism. Kaiser '247 teaches that it is desirable toinclude a valve in the air ejector to eliminate the “dead zone” in theair supply tube extending between the valve and the inlet to the pumpbody, and thereby eliminate the powder pulse “tailing effect”experienced in other powder pump designs. However, such an arrangementhas the disadvantage of a requiring a valve assembly adjacent to orwithin the ejector, which may not be practical or even possible in everyinstallation due to space or geometry constraints. These approaches havein common, that they primarily create a pulsed gas/air stream, whichaccelerates the particles to create a pulsed particle stream. However,such air pulses are difficult to control in stable manner, in particularfor higher pulse frequencies and higher particle flow rates.

Henceforth, the present invention aims at overcoming limitations of theknown systems, in particular with regard to pulse frequency so as toallow for higher production speeds, as well as with regard to higherthroughput on a per pad basis, so as to satisfy the requirements ofmodern absorbent article design.

As a further objective the invention provides a kit or pack ofindividual absorbent articles in a cost effective manner.

SUMMARY OF THE INVENTION

The present invention is a method of creating a pulsed stream ofparticles in a carrier means, which includes the steps of suspending afirst metered stream of particles in a carrier means, guiding this firststream to a pulsing means, accumulating a portion of these particles ina pulsing chamber of the pulsing means, which further includes aseparator means, and emptying the particles out of the pulsing means bya suction means, whereby the accumulation is performed by interruptingthe stream of particles as flowing from an inlet of the pulsing means toan outlet of the pulsing means by the separator means for not less than95%, preferably not less than 90%, more preferably not less than 75% andeven more preferably not less than 50% of said time of a pulse.

Preferably, the separator means rotates in the pulsing means. It is alsopreferred, that the suction means is an venturi-type ejector, or aring-jet-type coaxial ejector, preferably positioned in proximity to theoutlet of the pulsing means, and that the suction means is positioned inproximity to the outlet of the pulsing means. The present invention isparticularly suitable for creating pulses at a frequency of at least 10Hz preferably more than 15 Hz, even more preferably more than 20 Hz.

In a further aspect, the present invention is an apparatus for pulsing ametered stream of particular material in a carrier means comprising, ametering means, a pulsing means having an inlet, an outlet, a pulsingchamber located there between and comprising a separator means, and asuction means arranged in proximity of the outlet. The separator meansis arranged to interrupt said flow of particles between the inlet andthe outlet for not less than 95%, preferably not less than 90%, morepreferably not less than 75% and even more preferably not less than 50%of said time of a pulse. The separator means may be designed to notinterrupt the flow of the carrier means, which preferably is a gas, suchas air.

It is also preferred, that the suction means is an venturi-type ejector,or a ring-jet-type coaxial ejector, preferably positioned in proximityto the outlet of said pulsing means, and that the suction means ispositioned in proximity to the outlet of said pulsing means.

In a further aspect the invention relates to a kit or pack of individualabsorbent articles, the absorbent articles being produced by a method oflow standard deviation manufacturing, the kit or pack of absorbentarticles comprising at least 10 individual absorbent articles which havebeen produced consecutively by the method of low standard deviationmanufacturing, the absorbent articles each comprising a topsheet and abacksheet and an absorbent core encased between the topsheet and thebacksheet, the absorbent core comprising a first material providing fora first absorbent capacity and a second absorbent material providing fora second absorbent capacity, the absorbent core having a longitudinaldirection, the absorbent core comprising a front half and a rear half,the halves having equal length as measured in the longitudinaldirection, the front half of the absorbent core comprising more than 60%of the second absorbent capacity, the second absorbent materialcomprised by the absorbent material of each of the absorbent articleshaving a total weight, the kit or pack of absorbent articles having aaverage total weight taken as the average of the total weights of theparticulate absorbent material of individual articles, the kit or packof absorbent articles having a standard deviation of total weightcalculated based on the deviation of the total weight of the particulateabsorbent material of individual articles from the average total weight,wherein the standard deviation of total weight is less than 8%.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A, B, C, and D show schematically diagrams of pulse patterns.

FIGS. 2A and 2B show schematic presentation of an uninterrupted,continuous particle flow path (FIG. 2A), and an interrupted flow path(FIG. 2B).

FIGS. 3A and 3B show schematic presentations of an exemplary pulsingmeans according to the invention.

FIGS. 4A through 4C show exemplary embodiments for separator meansuseful in such a pulsing means.

DETAILED DESCRIPTION OF THE INVENTION

Within the context of the present description, the term “pulse” is usedto describe the time dependency of a particle flow in a certain,repeating pattern. This pattern can be described via the local flow ofmaterial per time interval (in units of g/sec) and a repeating frequencydefining a time interval for the pulse.

Thus, in FIG. 1A, a typical pulse pattern 100 is depicted, showing anexample for a repeating particle flow pulse. The pulse has a pulseduration 110, a pulse repeating time period 120 (defining a pulsefrequency), and a peak pulse flow rate 130. If there is no particle flowbetween two pulses, the minimum pulse flow rate 140 is equal to zero.The particle flow can be further described by the average flow rate 135.The particle flow can also be expressed by the particle density, definedby the volumetric flow of particles divided by volumetric flow of air.

In particular cases, the pulse can have two (or even more) plateaus witha second plateau flow rate 150 for a second plateau duration time 155(see FIG. 1B), which even further may be interrupted (see FIG. 1C),whereby a first pulse duration and frequency (145, 147) and a secondpulse duration and frequency (157, 159) can be distinguished.

The shown rectangular “pulse shape” is certainly often desired, butgenerally the shape will differ to a certain extent, and in the extreme,a can be formed by gradually increasing and decreasing flanks 170, 180(see FIG. 1D).

Within the context of the present description, the term “flow path” isused to describe the path of a moving object, such as a particle. A flowpath between two locations (such as cross-sectional areas 210 and 220 ofa tube 200 as shown in the schematic cross-sectional view in FIG. 2) iscalled uninterrupted, or continuous, if a particle can move from such alocation 210 (inlet) to another location 220 (outlet) withoutencountering a physical barrier, as indicated by the continuous arrows240. It is called interrupted, if a particle is hindered by physicalbarrier, such as schematically and exemplarily indicated by a rotaryvalve element 230. For this instance, there will be separated flow pathson both sides of the barrier, as indicated by the flow path arrows 245and 247 respectively. While, of course, also movements of fluids likegases can be described flow paths (and also both continuous as well asinterrupted ones), the term “particle” is used herein to describediscrete solid particles, for example in the context of disposableabsorbent articles it can be absorbent particles, or superabsorbentparticles, which are essentially dry particles having a

particle size which can range from several microns to severalmillimetres. Such particles can be suspended in a “carrier”, such as agas such as air.

Description of the Features of the Process and Apparatus

The present invention is not limited to a particular application, andflow rates, pulse frequencies can be varied in a broad range withoutdeparting from the essence of the present invention. However, thefollowing explanations will refer in certain aspects to specificexamples, which will be—without limiting the present invention to thisfield—the manufacture of disposable absorbent articles, such as babydiapers and the like.

Particle Flow Metering

Metering devices to provide well defined particle mass flow rates, inparticular constant predetermined flow rates, are well known in the art.Such a metering apparatus can include a hopper with, for example a screwfeeder and a scale or “loss-in-weight control”. A suitable meteringapparatus particularly suitable in the manufacture of absorbent articlesis an Acrison Volumetric Feeder, Model No. 405-105X-F, available fromAcrison, Inc. of Moonachie, N.J. Such a metering apparatus can beoperated to provide a mass flow rate of up to about 1500 kg/hr or more,preferably between 30 kg/hr and 1200 kg/hr.

The particle metering apparatus can be connected for further conductingthe metered particle stream to a connecting means. A typical example forsuch a connecting means is a tube having an inner diameter of about 2.5cm (about 1 inch). Preferably, the connector means does not have sharpedges or bends, as this might influence the stability of the particlestream.

If the metering apparatus and the pulsing means are appropriatelyarranged with regard to their relative positioning, there is no need fora carrier means to carry the particle from the metering apparatus to thepulsing means, but gravity would suffice to let the particles fall fromthe first to the second. However, often it can be advantageous to havesome carrier flow, such as air flow. If an additional carrier stream isused, this is preferably done at moderate carrier speed, and in apreferred embodiment as described hereinafter, carrier velocities ofbetween 1 and 20 m/sec have been found to be suitable. This carrierstream is further preferably steady to maintain a constant particlestream. In case of carrier flow fluctuations, these are preferably inphase with the pulsing frequency so as maintain stable conditions. Forthe described exemplary application in the manufacture of absorbentarticles, such a carrier flow can be created by having an opening to theambient in the connecting means, positioned close to the meteringapparatus. Suction as applied on the other side of the pulsing means(and discussed hereinafter) can suffice to provide stable particle flowconditions.

An important element of the present invention is the pulsing means,arranged (in following the flow path direction of particles) after theconnection means, and operated so as to create the pulsed particle flow.

The pulsing means is designed to allow interrupting the particle flow ina repeating manner, whereby the particles are accumulated during thisinterruption period and released thereafter. The pulsing means comprisesan inlet, through which the particles can enter the pulsing means, anoutlet, through which the particles can exit the pulsing means, apulsing chamber positioned between the inlet and the outlet providingsufficient space to allow accumulation of at least some of theparticles, and a separator means, positioned in this pulsing chamber.

While it may interrupt the carrier flow for a part of a cycle time,there has to be a certain time, during which the carrier flow path and aparticle flow path are connected from the inlet of the pulsing means tothe outlet of the pulsing means. Without wishing to be bound by theexplanation, it is believed, that this period is important to stabilizethe flow properties of the carrier.

A pulsing means suitable for applications such as in the production ofabsorbent articles can be designed to pulse a stream of absorbentparticles, with typical sizes in the range of several micron to fewmillimetres, and with particle flow rates in the range of 1500 kg/hr ormore. For such an application, pulse frequencies can range from about 3to about 35 Hz or even more.

A suitable pulsing means in the context of the present invention impactson the particles directly in a valve-type function. This is to be seenin contrast to other approaches, wherein a pulse of a carrier means,such as a pulsed air stream, impacts on the particles. The valvetype-operation can be realized by various designs, such as oscillatingslide valves, iris-type valves, diaphragm-type valves, rotating,apertured disks similar to the design as described in U.S. Pat. No.4,800,102 (Takada).

A further exemplary and preferred pulsing means builds on the principlesof a rotary valve, as is well known in the art as a closure element,such as for a storage container for particulate material. Therein,however, they are designed to hermetically separate the storagecontainer from the subsequent system, such as a pneumatic transportsystem, without providing a certain period of the cycle time with acontinuous particle flow path—see as one of various exemplarydisclosures U.S. Pat. No. 3,974,411 (Miller). Alternatively, rotaryvalves are known to provide for an “open-close” functionality (i.e. noaccumulation functionality as in the present case), such as described inU.S. Pat. No. 4,393,892 (Di Rosa).

One particular benefit of such rotary designs is the avoidance ofoscillatory movements, which, in particular for higher frequencies,would create either undesirably heavy (and hence difficult toaccelerate) elements, or designs with a non-satisfactory reliability. Incontrast to these, a rotary design can keep the separator meansoperating at a constant speed, thus allowing a much more stableoperation even for high pulse frequencies.

As depicted in a schematic, cross-sectional view—see FIG. 3A—such apreferred rotary pulsing means 310 can comprise a rotating separatormeans 330, rotatably mounted in a pulsing chamber 320, having acylindrical shape with a diameter and a height, of the pulsing means310. Further indicated is a particle flow path 370, freely connectingthe inlet 340 and the outlet 350, without being obstructed by aseparator means 330. FIG. 3B schematically shows the same equipment(with equal numerals indicating same elements), now at a differentrotational position of the separator means 330, such that there is nofree particle path connection between the inlet 340 and the outlet 350,but there is a filling flow path 372 disconnected from the emptying flowpath 374.

When, during the operation, the separator means 330, as it rotates at apredetermined frequency, it takes the position of interrupting theparticle flow path, the particles, arriving at the inlet 340 at anessentially constant stream will accumulate in that part of the pulsingchamber 320, which is connected to the inlet 340. During this time,essentially no particles will exit the pulsing means through the outlet350. During the period where the separator means 330 is in a position soas to not interrupt the particle flow path, the chamber will essentiallybe emptied, and some particles may penetrate through the completechamber, depending on the relative speed of the particles compared tothe rotational speed. If these speeds are appropriately chosen, therotation of the separator means can impact on the accumulated particlesand accelerate these out of the chamber.

For the exemplary application in the production process of manufacturingdisposable absorbent articles, the diameter of the pulsing chamber cansuitably be in the range of 50 to 500 mm, with a diameter of 120 mmworking well. The thickness dimension (i.e. along an axis perpendicularto the plane of FIG. 3) can suitably be in the range of about 10 toabout 100 mm, with a thickness of 50 mm found to be working well.

For a symmetrically shaped separator means 330 as indicated in FIG. 3,one 360° rotation of the separator means will result in creating twopulses, i.e. the pulse frequency is twice the rotational frequency.

The separator means 330 can be an essentially rectangular bar with itsends being rounded to fit smoothly into the cylindrical separatorchamber without undue friction or gapping. The separator means can alsohave different shapes, provided it enables the separation function bysmoothly fitting to the walls of the separator chamber. For example, itcan have essentially oval cross-section, or ellipsoidal shape, or othersas indicated in FIG. 4 A to C (see separator means 430 a-430 c). Theshape of the separator means can be used to design the shape of theresulting pulses, in particular to create stepped pulses, or twosubsequent pulses with differing pulse form. An asymmetric design of theseparator means results in two pulses per one 360° rotation of theseparator means, each with a different pulse shape. FIG. 4B shows anessentially semi-circular cross-section. Such a design would provide oneaccumulation phase for one rotation of the separator means.

While in FIGS. 2 and 3 the inlet and the outlet have been shown in aparticular relative positioning (in a 180° degree arrangement), thisdoes not need to be the case. It will be clear to a skilled person thatthe relative positioning of inlet and outlet to each other will impacton the pulse shape in cooperation with the shape of the separator means.Thus, for many applications, the 180° design will be most suitable, butthis does not need to be always the most preferred execution. Also, forthe inlet and the outlet duct there does not need to be a radialarrangement of the connector means (as shown in FIGS. 2 and 3), but moretangential or even curved tangential designs can be preferred. It hasbeen found that more tangential outlet could deliver a significantlyhigher throughput of particles compared to a perpendicular outlet.Similarly, the size of the inlet and outlet openings can be equal, suchthat the projected area ratio of the two is about one. A skilled personwill readily find out the balance of simplicity of design, match withother fittings of the apparatus, and, of course, the desire formaintaining the pulse shape adequately.

In order to transfer the particles from the pulsing chamber to thefurther steps of the process, suction is applied to empty the pulsingchamber effectively. In the exemplary process of manufacturing absorbentarticles, the forming of such articles often comprises the step oflaying down absorbent materials—such as the particles undergoing thepulsing step—on a forming means, such as a permeable carrier, byapplying vacuum on the side facing away from the feeding and pulsingmeans. Then, this vacuum can suffice to create suction for emptying theseparator chamber, and an opening positioned close to the outlet of thepulsing chamber can provide sufficient carrier flow.

Under certain conditions it will be desired to not only empty thepulsing chamber quickly, but also to accelerate the particles to arelatively higher speed. Such instances can be for example the mixing ofthese particles with other matter, such as fibres, like cellulosefibres, staple synthetic fibres meltblown fibres or the like, in thecase when forming absorbent articles. Such acceleration shouldpreferably not distort the pulse shape as created by the pulsing means.Then, a particular suction means can be positioned between the pulsingchamber and the forming means.

It is important, that the suction means does not distort the shape ofthe pulse too much, such as for example a rotary ventilator would do. Ithas been found suitable to use an additional stream of carrier, such asgas or air, so as to accelerate the carrier stream and thereby also theparticle pulse stream. A venturi type ejector has been found suitable ifused to provide moderate suction and hence acceleration. For highersuction and acceleration, such venturi type ejectors tend to provide anon-uniform flow pattern across the cross-section, generally in theshape a pronounced parabolic profile. However, in order to maintain theshape of the pulse, a more rectangular, or “plug flow” profile ispreferred.

A suitable element to provide such flow characteristics has been foundin a coaxial eductor. Two design principles have been found to beparticularly suitable each for certain circumstances:

a) A ring jet ejector, which use is based on the well known Coandaeffect, has been found to be working extremely well especially for lowerparticle density streams (i.e. lower average particle flow rates) whichneed to get accelerated to very high speeds. This is due to the factthat Coanda effect based ejector designs deliver the highest suction airvolume stream at least for carrier-only systems. Coanda flow tends tostall if the particle density is too high.

-   -   The design of these ejectors even more preferably has a fixed        gap design. Such ejectors can be produced by EXAIR (Cincinnati,        Ohio, USA) under the designation Air Amplifier 6032, or Krahnen        (Cologne, Germany) under the designation RJ25. It has further        been found, that such ejectors can provide velocities of the        carrier of up to of 80 m/sec or even more with a much more        levelled velocity profile.

b) A coaxial ejector designed to use the Venturi effect has been foundto be less critical to higher particle densities (volumetric flow ofparticles divided by volumetric flow of air). Such ejectors stilldeliver plug flow type of speed profiles, which preserve the pulse, asdelivered from the separator mean. Such ejectors can be produced byEXAIR (Cincinnati, Ohio, USA) Line Vac 6063. These devices may needmodification to increase suction air by increasing the motive air, suchas by increasing the number of air throughput holes.

A particular benefit of such an arrangement is, in addition to providinga sharply defined pulse, an even profile throughout this pulse. Inparticular, it allows avoiding of a bias in the profile, such as aparticle distribution to the left or right side of a system.

In order to allow a more effective emptying of the pulsing chamber, thesuction means is preferably positioned in the proximity of the outlet ofthe chamber, more preferable immediately adjacent thereto. To change theprofile this may be changed according to the application need i.e., ifthe slope of the density change should be less steep a longer distancewould be appropriate.

Once the pulsed particle stream has been created, and optionallyaccelerated, the transfer to the downstream process steps can be done inany conventional manner as well know to the skilled person, and asdescribed in the above referenced documents. As indicated in the above,such process steps can include mixing of the pulsed particle stream withother materials, such as in the exemplary application of formingabsorbent articles with fibres, which can be a continuous stream, ordiscontinuous. The pulsed stream can also be laid down on a formingmeans, such as a screen or web permeable to the carrier but not to theparticles. Preferably, the distance to the subsequent process steps isnot too long so as to allow maintaining the pulse shape.

Preferred Products and Kits or Packs of Products

Preferably the method of creating a pulsed stream of particles is usedfor the production of absorbent articles, such as baby diapers, trainingpants, adult diapers or incontinence products, sanitary napkins and thelike.

These articles are known to typically comprise a topsheet, facing thewearer when the article is used, and a backsheet. Topsheet and backsheetare typically joined and encase the absorbent core.

The absorbent core may comprise any absorbent material that is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and certainother body exudates. The absorbent core may comprise a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp, which is generallyreferred to as air felt. Examples of other suitable absorbent materialsinclude creped cellulose wadding; melt blown polymers, includingco-form; chemically stiffened, modified or cross-linked cellulosicfibers; tissue, including tissue wraps and tissue laminates; absorbentfoams; absorbent sponges; superabsorbent polymers; absorbent gellingmaterials; or any other known absorbent material or combinations ofmaterials.

Preferred absorbent cores according to the present invention comprise afirst material providing for a first absorbent capacity and a secondabsorbent material providing for a second absorbent capacity. Preferablythe first material is a fibrous absorbent material and the secondabsorbent material is a particulate absorbent material and mostpreferably a superabsorbent material. Most preferably the fibrousmaterial has a substantially uniform basis weight over the whole area ofthe core. If the core comprises fibrous layers which do not comprisesuperabsorbent material, e.g., do serve for example as acquisition ordistribution layers, the basis weight of these layers does not need tobe uniform, and it is preferred that only those fibrous layers whichserve as containment means for superabsorbent material have uniformbasis weight.

In another embodiment of the present invention the first material is notan absorbent material, i.e., its absorbent capacity is zero oressentially zero. Such a material can serve to maintain the structureand integrity of the absorbent core. For example it can be an adhesivematerial.

Preferably the first material is present at a low basis weight,preferably less than 130 g/m², 120 g/m², 110 g/m², 100 g/m², 90 g/m², 80g/m², 70 g/m², 60 g/m², 50 g/m², 40 g/m² or even less than 30 g/m².

Preferred articles according to the present invention achieve arelatively narrow crotch width, which increases the wearing comfort. Apreferred article according to the present invention achieves a crotchwidth of less than 100 mm, 90 mm, 80 mm, 70 mm, 60 mm or even less than50 mm.

Absorbent articles are typically marketed in kits or packs comprisingmultiple individual absorbent articles, for example at least 10, 12, 15,20, 25 or 30 individual absorbent articles are sold together. Consumersexpect each individual absorbent article to deliver the same satisfyingperformance, namely in respect of absorbency. It is most critical toprovide sufficient absorbency in the front half of the articles. Thefront half of the article is typically the area to receive dischargedurine, which is then to be stored in the front half of the absorbentcore.

The front half of the absorbent core should therefore comprise most ofthe absorbent capacity of the core. Preferably most the absorbentcapacity of the core comprising a first and a second absorbent materialis provided by the second absorbent material, which is preferably aparticulate material and most preferably a particulate superabsorbentmaterial. Preferably, the front half of said absorbent core comprisesmore than 60% of the absorbent capacity of the second absorbentmaterial, more preferably more than 65%, 70%, 75%, 80%, 85%, 90% or 95%.

As consumers expect each individual absorbent article to deliver thesame satisfying performance, but as on the other hand absorbentmaterials and in particular superabsorbent materials are costly, it isdesirable to provide a kit or pack of individual absorbent articleswherein each individual absorbent article comprises about the sameamount of absorbent materials and in particular superabsorbentmaterials.

An appropriate measure for the amount of absorbent material is the totalweight of the absorbent material. It is desirable that the total weightof the absorbent material and namely of superabsorbent material in eachindividual absorbent article in a kit or pack is about the same as theaverage total weight of that material in the kit or pack. In otherwords, the standard deviation of the total weight of that materialshould be low. It is preferred that the standard deviation of totalweight is less than 8% or less than 7%, and preferably less than 6%, andyet preferably less than 5%, and yet preferably less than 4%, and yetpreferably less than 3%, and yet preferably less than 2%.

The disclosed process enables to produce kits or packs of absorbentarticles with very uniform distribution of the amount of superabsorbentmaterial.

A definition of standard deviation can be found in the book “Taschenbuchder Mathematik” by I. N. Bronstein, K. A. Semendjajew: 23. Auflage,Verlag Harri Deutsch, Thun und Frankfurt/Main (1987) ISBN 3-87144-492-8,and therein in equation (5.31) on page 666.

The present invention allows to achieve the above standard deviationswhere fast processes of manufacturing are employed. The above standarddeviations can achieved at a production lines yielding more than 100,200, 300, 400, 500, or even more than 600 absorbent articles per minute.

These articles are typically produced in a process of low standarddeviation manufacturing for consecutive production of many absorbentarticles. Not all article produced in such process may meet the desiredquality standards. Some articles may be considered faulty and aretherefore either manually or automatically excluded from being sold to aconsumer and e.g. not packed. If, for example, eleven or twelve articlesare produced and one or two articles are considered faulty, theremaining ten articles are herein considered to be consecutivelyproduced.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method of producing absorbent articles, the method comprising:suspending particles in a gas carrier to form suspended particles;creating a series of pulses from the suspended particles, wherein eachpulse in the series of pulses is created by: accumulating at least someof the suspended particles in a pulsing chamber to form accumulatedparticles on a rotary separator, and releasing at least some of theaccumulated particles by rotating the rotary separator to create eachpulse; and suctioning each pulse from the series of pulses onto aforming surface for the absorbent articles.
 2. The method of claim 1,wherein the creating includes: accelerating at least some of theaccumulated particles with the rotary separator to form acceleratedparticles; and releasing at least some of the accelerated particles byrotating the rotating separator.